Dodge ZB 2005 User manual

SERVICE MANUAL
2005
ZB
NO PART OF THIS PUBLICATION MAY BE
REPRODUCED, STORED IN A RETRIEVAL
SYSTEM, OR TRANSMITTED, IN ANY FORM OR
BY ANY MEANS, ELECTRONIC, MECHANICAL,
PHOTOCOPYING, RECORDING, OR OTHERWISE,
WITHOUT THE PRIOR WRITTEN PERMISSION
OF DAIMLERCHRYSLER CORPORATION.
DaimlerChrysler Corporation reserves the right to make changes in design or
to make additions to or improvements in its products without imposing any
obligations upon itself to install them on its products previously manufactured.
Copyright © 2004 DaimlerChrysler Corporation
81-526-05015

FOREWORD
The information contained in this service manual has been prepared for the professional automotive tech-
nician involved in daily repair operations. Information describing the operation and use of standard and
optional equipment is included in the Owner’s Manual provided with the vehicle.
Information in this manual is divided into groups. These groups contain description, operation, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and compo-
nents. To assist in locating a group title page, use the Group Tab Locator on the following page. The solid bar
after the group title is aligned to a solid tab on the first page of each group. The first page of the group has
a contents section that lists major topics within the group. If you are not sure which Group contains the infor-
mation you need, look up the Component/System in the alphabetical index located in the rear of this manual.
A Service Manual Comment form is included at the rear of this manual. Use the form to provide
DaimlerChrysler Corporation with your comments and suggestions.
Tightening torques are provided as a specific value throughout this manual. This value represents the
midpoint of the acceptable engineering torque range for a given fastener application. These torque values are
intended for use in service assembly and installation procedures using the correct OEM fasteners. When
replacing fasteners, always use the same type (part number) fastener as removed.
DaimlerChrysler Corporation reserves the right to change testing procedures, specifications, diagnosis,
repair methods, or vehicle wiring at any time without prior notice or incurring obligation.

GROUP TAB LOCATOR
Introduction
0Lubrication & Maintenance
2Suspension
3Differential & Driveline
5Brakes
6Clutch
7Cooling
8A Audio/Video
8B Chime/Buzzer
8E Electronic Control Modules
8F Engine Systems
8G Heated Systems
8H Horn
8I Ignition Control
8J Instrument Cluster
8L Lamps
8N Power Systems
8O Restraints
8Q Vehicle Theft Security
8R Wipers/Washers
8W Wiring
9Engine
11 Exhaust System
13 Frame & Bumpers
14 Fuel System
19 Steering
21 Transmission/Transaxle
22 Tires/Wheels
23 Body
24 Heating & Air Conditioning
25 Emissions Control
Component and System Index
Service Manual Comment Forms (Rear of Manual)

GROUP TAB LOCATOR
Introduction
0Lubrication & Maintenance
2Suspension
3Differential & Driveline
5Brakes
6Clutch
7Cooling
8A Audio/Video
8B Chime/Buzzer
8E Electronic Control Modules
8F Engine Systems
8G Heated Systems
8H Horn
8I Ignition Control
8J Instrument Cluster
8L Lamps
8N Power Systems
8O Restraints
8Q Vehicle Theft Security
8R Wipers/Washers
8W Wiring
9Engine
11 Exhaust System
13 Frame & Bumpers
14 Fuel System
19 Steering
21 Transmission/Transaxle
22 Tires/Wheels
23 Body
24 Heating & Air Conditioning
25 Emissions Control
Component and System Index
Service Manual Comment Forms (Rear of Manual)

INTRODUCTION
TABLE OF CONTENTS
page page
BODY CODE PLATE
DESCRIPTION ..........................1
E-MARK LABEL
DESCRIPTION ..........................1
FASTENER IDENTIFICATION
DESCRIPTION ..........................2
FASTENER USAGE
DESCRIPTION
FASTENER USAGE .....................4
THREADED HOLE REPAIR ...............4
INTERNATIONAL SYMBOLS
DESCRIPTION ..........................4
MANUFACTURE PLATE
DESCRIPTION ..........................5
METRIC SYSTEM
DESCRIPTION ..........................5
TORQUE REFERENCES
DESCRIPTION ..........................7
VECI LABEL
DESCRIPTION ..........................9
VEHICLE IDENTIFICATION NUMBER
DESCRIPTION ..........................9
VEHICLE CERTIFICATION LABEL
DESCRIPTION .........................10
BODY CODE PLATE
DESCRIPTION
This vehicle does not require a Body Code Plate
due to limited optional equipment and colors.
E-MARK LABEL
DESCRIPTION
An E-mark Label (Fig. 1) is located on the rear
shut face of the driver’s door. The label contains the
following information:
•Date of Manufacture
•Month-Day-Hour (MDH)
•Vehicle Identification Number (VIN)
•Country Codes
•Regulation Number
•Regulation Amendment Number
•Approval Number
Fig. 1 E-MARK LABEL
1 - COUNTRY CODE
2 - REGULATION NUMBER
3 - APPROVAL NUMBER
4 - AMENDMENT NUMBER
ZB INTRODUCTION 1

FASTENER IDENTIFICATION
DESCRIPTION
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater
the bolt strength. Identification is determined by the
line marks on the top of each bolt head. The actual
bolt strength grade corresponds to the number of line
marks plus 2. The most commonly used metric bolt
strength classes are 9.8 and 10.9. The metric
strength class identification number is imprinted on
the head of the bolt. The higher the class number,
the greater the bolt strength. Some metric nuts are
imprinted with a single-digit strength class on the
nut face. Refer to the Fastener Identification and
Fastener Strength Charts.
BOLT MARKINGS AND TORQUES - METRIC
Bolt Markings 8.8/8.9 10.9 12.9
Bolt Dia. N·m Ft. Lbs. N·m Ft. Lbs. N·m Ft. Lbs.
6 12 105* 14 120* 16 12
8 25 250* 32 23 38 28
10 54 40 60 45 74 55
12 95 70 108 80 135 100
14 155 115 175 130 216 160
16 243 180 324 210 324 240
* Inch Lbs.
BOLT MARKINGS AND TORQUES - U. S. CUSTOMARY
Bolt Markings Grade 5 Grade 8
Bolt Dia. N·m Ft. Lbs N·m Ft. Lbs
1/4 - 20 10 95* 14 125*
1/4 - 28 10 95* 17 150*
5/16 - 18 22 200* 30 270*
5/16 - 24 26 240* 33 300*
3/8-1640305540
3/8-2447356045
7/16-1468508865
7/16-2074559570
1/2 - 13 101 75 135 100
1/2 -20 115 85 150 110
9/16 - 12 135 105 182 135
9/16 - 18 155 115 202 150
5/8 - 11 202 150 263 195
5/8 - 18 215 160 284 210
3/4 - 10 230 170 297 220
3/4 - 16 236 175 304 225
7/8 - 14 405 300 540 400
* Inch Lbs.
2 INTRODUCTION ZB

FASTENER STRENGTH
ZB INTRODUCTION 3
FASTENER IDENTIFICATION (Continued)

FASTENER USAGE
DESCRIPTION
FASTENER USAGE
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL INJURY.
Fasteners and torque specifications references in
this Service Manual are identified in metric and SAE
format.
During any maintenance or repair procedures, it is
important to salvage all fasteners (nuts, bolts, etc.)
for reassembly. If the fastener is not salvageable, a
fastener of equivalent specification must be used.
THREADED HOLE REPAIR
Most stripped threaded holes can be repaired using
a Helicoilt. Follow the vehicle or Helicoiltrecommen-
dations for application and repair procedures.
INTERNATIONAL SYMBOLS
DESCRIPTION
The graphic symbols illustrated in the following
International Control and Display Symbols Chart are
used to identify various instrument controls. The
symbols correspond to the controls and displays that
are located on the instrument panel.
INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Wind screen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
4 INTRODUCTION ZB

MANUFACTURE PLATE
DESCRIPTION
The Manufacturer Plate (Fig. 2) is located in the
engine compartment on the passenger side rear cor-
ner of the hood. The plate contains five lines of infor-
mation:
1. Vehicle Identification Number (VIN)
2. Gross Vehicle Mass (GVM)
3. Gross Train Mass (GTM)
4. Gross Front Axle Rating (GFAR)
5. Gross Rear Axle Rating (GRAR)
METRIC SYSTEM
DESCRIPTION
The metric system is based on quantities of one,
ten, one hundred, one thousand and one million.
The following chart will assist in converting metric
units to equivalent English and SAE units, or vise
versa.
CONVERSION FORMULAS AND EQUIVALENT VALUES
MULTIPLY BY TO GET MULTIPLY BY TO GET
in-lbs x 0.11298 = Newton Meters
(N·m) N·m x 8.851 = in-lbs
ft-lbs x 1.3558 = Newton Meters
(N·m) N·m x 0.7376 = ft-lbs
Inches Hg
(60° F) x 3.377 = Kilopascals (kPa) kPa x 0.2961 = Inches Hg
psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi
Inches x 25.4 = Millimeters (mm) mm x 0.03937 = Inches
Feet x 0.3048 = Meters (M) M x 3.281 = Feet
Yards x 0.9144 = Meters M x 1.0936 = Yards
mph x 1.6093 = Kilometers/Hr.
(Km/h) Km/h x 0.6214 = mph
Feet/Sec x 0.3048 = Meters/Sec (M/S) M/S x 3.281 = Feet/Sec
mph x 0.4470 = Meters/Sec (M/S) M/S x 2.237 = mph
Kilometers/Hr.
(Km/h) x 0.27778 = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr. (Km/h)
Fig. 2 MANUFACTURER PLATE
ZB INTRODUCTION 5